Occasionally, in volume device manufacturing, a large number of particles may be generated on cleaned Si wafers. Surface (ionic, organic and/or metallic) contamination is generally suspected. However, conventional chemical analysis techniques for contamination are generally not able to distinguish between Si wafers with good and poor particle performance. No suspicious chemicals and elements were detected from any wafers regardless of characterization techniques. Surface photovoltage (SPV) measurement barely showed the differences between wafers with good and poor particle performance. Multiwavelength room temperature photoluminescence (RTPL) showed significant differences in intensity between them, indicating the presence of surface quality variations. Contamination related yield loss is a major failure mode in advanced silicon (Si) device volume manufacturing.1 Silicon wafers are routinely inspected at various stages using in-line and off-line characterization techniques. Incoming wafers are inspected for ionic, inorganic and metal contamination. As device dimensions are shrinking, contamination related device yield loss tends to increase.Conventional incoming wafer contamination test techniques include ion chromatography (IC) for ionic contamination, gas chromatography with flame ionization detector (GC-FID) for organic contamination and inductive coupled plasma-mass spectroscopy (ICP-MS) for metal contamination.2-4 Other X-ray techniques, such as total X-ray fluorescence (TXRF) and wavelength dispersive X-ray fluorescence (WDXRF) techniques, are also used as in-line metal contamination techniques. 4 Most techniques have detection limits in the range of ppm ∼ ppb.2-4 They are not sensitive enough for certain types of process anomalies.In this study, the root cause of a recent incident generating a large number of particle/defects was investigated using surface photovoltage (SPV) 5 and multiwavelength room temperature photoluminescence (RTPL) 6,7 measurements. Figure 1 shows the flow of Si wafer inspection and process steps. The wafers in front opening shipping boxes (FOSBs) were transferred into front opening unified pods (FOUPs). The wafers were cleaned in deionized (DI) water and the surface inspected for particles and defects. Typically, all wafers pass the inspection. Silicon dioxide (SiO 2 ) films were deposited on 300 mm Si (100) wafers in a plasma enhanced chemical deposition (PECVD) system using liquid tetraethyl orthosilicate (TEOS: Si(OC 2 H 5 ) 4 ) as a source of Si. The Si wafers with PECVD SiO 2 films were inspected for particles and defects again.
ExperimentalThree batches (A, B and C) of 25 Si wafers (3 × 25 = 75 wafers) with native oxide (SiO 2 /Si) were allocated for this study. Four wafers per batch were used for chemical analyses (IC for ionic contamination, GC-FID for organic contamination and ICP-MS for metal contamination). For SPV measurements, the contact potential difference (or probe potential), V cpd , was mapped under green light-emitting-diode (LED) illumination at a peak wavelen...